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VersaFlo TP
Direct Coupled In-Line Single Stage
Circulator Pumps
Installation and operating instructions
L-TP-TL-001 10/06
PRINTED IN THE USA
www.grundfos.com
LIMITED WARRANTY U.S.A. Canada Mexico
GRUNDFOS Pumps Corporation GRUNDFOS Canada, Inc. Bombas GRUNDFOS de Mexico S.A. de C.V.
17100 West 118th Terrace 2941 Brighton Road Boulevard TLC No. 15
Products manufactured by GRUNDFOS PUMPS CORPORATION (GRUNDFOS) are warranted Olathe, Kansas 66061 Oakville, Ontario Parque Industrial Stiva Aeropuerto
Phone: +1-913-227-3400 L6H 6C9 C.P. 66600 Apodaca, N.L. Mexico
to the original user only to be free of defects in material and workmanship for a period Telefax: +1-913-227-3500 Phone: +1-905-829-9533 Phone: +1-52-81-8144 4000
Telefax: +1-905-829-9512 Telefax: +1-52-81-8144 4010
of 24 months from date of installation, but not more than 30 months from date of
manufacture. GRUNDFOS' liability under this warranty shall be limited to repairing or
replacing at GRUNDFOS' option, without charge, F.O.B. GRUNDFOS' factory or authorized
service station, any product of GRUNDFOS manufacture. GRUNDFOS will not be liable for
any costs of removal, installation, transportation, or any other charges which may arise
in connection with a warranty claim. Products which are sold but not manufactured by
GRUNDFOS are subject to the warranty provided by the manufacturer of said products and
not by GRUNDFOS' warranty. GRUNDFOS will not be liable for damage or wear to products
caused by abnormal operating conditions, accident, abuse, misuse, unauthorized alteration
or repair, or if the product was not installed in accordance with GRUNDFOS' printed
installation and operating instructions.
To obtain service under this warranty, the defective product must be returned to the
distributor or dealer of GRUNDFOS products from which it was purchased together
with proof of purchase and installation date, failure date, and supporting installation
data. Unless otherwise provided, the distributor or dealer will contact GRUNDFOS or
an authorized service station for instructions. Any defective product to be returned to
GRUNDFOS or a service station must be sent freight prepaid; documentation supporting
the warranty claim and/or a Return Material Authorization must be included if so
instructed.
Please leave these instructions with the pump for future reference.
Notes Contents
Page Page
1. Pre-Installation Checklist 4 4.1.4 Pump Lubrication 9
1.1 Confirm You Have the 4 4.1.5 Motor Lubrication 9
Right Pump
4.1.6 Lubrication Schedule 9
1.2 Check the Condition of 4
4.1.7 Periodic Safety Checks 9
the Pump
4.1.8 Service Conditions 10
1.3 Electrical Requirements 4
4.1.9 Rapid Cycling 10
1.4 Is the Application Correct 4
for This Pump? 4.1.10 Freeze Protection 10
1.5 Read This Guide Thoroughly 5 5. Troubleshooting 10
2. Installation Procedures 5 5.1 Preliminary Checks 10
2.1 Electrical Preparation 5 5.1.1 Supply Voltage 10
2.1.1 Terminal Box Position 5 5.1.1.1 How to Measure 10
2.1.2 Single-Phase Motors 5 5.1.1.2 Evaluation 10
2.1.3 Three-Phase Motors 5 5.1.2 Current Measurement 10
2.1.4 Other Wiring Considerations 5 5.1.2.1 How to Measure 10
2.2 Piping Considerations 5 5.1.2.2 Evaluation 10
2.3 Installing the Pump 6 5.1.3 Winding Resistance 11
2.3.1 Pump Location 6 5.1.3.1 How to Measure 11
2.3.2 Position in Piping System 6 5.1.3.2 Evaluation 11
2.3.3 Proper Orientation 6 5.1.4 Insulation Resistance 11
(Lead to Ground)
2.3.4 Direction of Flow for 6
Specific Applications 5.1.4.1 How to Measure 11
2.3.5 Suggested Accessories 6 5.1.4.2 Evaluation 11
2.4 Electrical Hookup 6 5.2 Diagnosing Specific Problems 12
3. Starting the Pump the 6
First Time
3.1 Prime the Pump 6
3.1.1 In Closed/Open System 6
Where Water Source is
Above the Pump
3.1.2 In Open Systems 7
3.2 Check the Direction of 7
Rotation
3.3 Starting and Adjusting 7
4. Maintenance 7
4.1 Servicing the Pump Head 7
4.1.1 Step 1: Remove the Pump 7
Head
4.1.1.1 Assembly 8
4.1.2 Step 2: Re-Install the Pump 8
Head
4.1.3 Motor Replacement 9
4.1.3.1 Disassembly 9
14
Safety Warning 1.2 Check the Condition of the Pump
Read This Booklet The shipping carton your pump came in
This booklet is designed to help a certified is designed around your pump during pro- Correct it by...
duction to prevent damage. As a precau-
installer begin operation of and trouble- If no voltage at motor, check feeder panel for tripped circuits.
tion, it should remain in the carton until
shoot Grundfos VersaFlo TP pumps. This you are ready to install it. At that point, Replace blown fuses or reset circuit breaker. If new fuses blow or circuit breaker trips, the terminal box wiring must be
booklet should be left with the owner of look at the pump and examine it for any checked.
the pump for future reference and infor- damage that may have occurred during Replace burned heaters or reset. Inspect starter for other damage. If heater trips again, check the supply voltage and
mation regarding its operation. Should the shipping. Examine any other parts of the starter holding coil.
owner experience any problems with the shipment as well for any visible damage.
If no voltage, check the control circuit fuses. If there is voltage, check the holding coil for shorts. Replace bad coil.
pump, a certified professional should be
contacted. 1.3 Electrical Requirements
Replace worn or defective parts.
Electrical Work Check the motor nameplate to determine
the proper voltage, phase, and frequency If the motor windings are open or grounded, replace the motor.
All electrical work should be performed by required. The voltage must be within 10%
a qualified electrician in accordance with of the specified motor nameplate voltage.
the latest edition of the National Electrical Dual volt-age motors must be internally
Code, local codes and regulations. wired to match the electrical supply. A When the meter is connected, the needle should jump toward 0 ohms and slowly drift back to infinity. Replace
Shock Hazard wiring connection diagram is affixed to the capacitor if defective.
motor.
A faulty motor or wiring can Fig. 1 Correct wiring and change leads as required.
cause electrical shock that
could be fatal, whether
touched directly or conducted Refill the pump, replace lug and start the pump. Long suction lines must be filled before starting the pump.
through standing water. For this reason, SPEC
proper grounding of the pump to the pow- Clean and replace. Re-prime the pump.
VOLTAGE
HOOKUP
FRAME SER
LOW
Nameplate
er supply's grounding terminal is required H.P.
VOLTS Wiring
for safe installation and operation. AMPS Diagram
Reduce suction lift by lowering pump, increasing suction line size or by removing high friction-loss fittings.
R.P.M. (in this case, for
a dual voltage
The ground wire should be a copper HZ
VOLTAGE
HOOKUP
PH CLASS
HIGH
12 5
2.3.4 Direction of Flow for Specific Fig. 7 If any one ohm value is less than normal
Minimum Pumping Rates: Applications (-25%), that motor winding may be starting
too short. If any one ohm value is greater
TP32,TP40,TP50. . . . . . . . . . . . . . . . . . . . 8 GPM Arrows on the flanges of the pump volute
than normal (+25%), the winding may
show the flow direction of water through
TP80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GPM be starting too open. If some values are
the pump.
high and some are low, the leads may be
TP100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 GPM connected incorrectly, or they may have a
Pumps used to circulate domestic water
should ALWAYS be installed in a vertical break in the insulating jacket.
The bypass should be routed back to a heat section of the circulating pipe and pump
5.1.4 Insulation Resistance (Lead to
dissipating source or to drain, depending upwards, and an effective air vent should
Ground)
on the liquid being pumped and local codes. be used in the same vertical section of pipe.
5.1.4.1 How to Measure
If the pump must be installed in a vertical
2.3 Installing the Pump pipe pumping down, an air vent should be 1. Burned contacts on motor starter. Turn off power and disconnect the supply
2.3.1 Pump Location installed at the highest point before the power leads in the pump terminal box.
2. Loose terminals in starter/terminal box
pump. Using an ohmmeter, set the scale selector
The pump should be installed in a dry, or possible wire defect.
to R x 100 and zero adjust the meter
well-ventilated area which is not subject to 2.3.5 Suggested Accessories 3. Too high or too low supply voltage. by touching the two ohmmeter leads
freezing or large variations in temperature. together. Touch one ohmmeter lead to a
Isolation valves should be installed on 4. Motor windings are shorted or
The pump should never be mounted motor lead and one to ground. Repeat for
each side of the pump to avoid having to grounded. Check winding and insulation
within six inches of any obstruction or hot each lead.
drain the system if the pump needs to be resistances.
surface. cleaned or repaired. Fig. 9
5. Pump is damaged causing a motor
Pumps to be installed outdoors or in a Check valve should be installed in the overload.
dusty environment should be ordered with discharge pipe.
a totally-enclosed-fan-cooled motor (TEFC) 5.1.3 Winding Resistance
attached to prevent motor failure. Plugged tee or capped pipe should be
installed in the suction line to fill the pump 5.1.3.1 How to Measure
2.3.2 Position in Piping System and pipe before start-up, especially if the Turn off power and disconnect the
Do not mount the pump at the highest or system is not pressurized. supply power leads in the pump terminal
lowest point in the piping system. Vibration isolators should be used in box. Using an ohmmeter, set the scale
noise-sensitive areas to prevent vibra-tion selector to R x 1 and zero adjust the meter 5.1.4.2 Evaluation
If the pump is installed at the highest point by touching the two ohmmeter leads
in the piping system, it may experience from being transmitted to the structure. The resistance values for new motors must
together.
reduced performance and increased noise Relief valve of bypass line should be exceed 1,000,000 ohms. If they do not,
due to air trapped in the pump. installed to allow sufficient water to Touch the leads of the ohmmeter to two replace the motor.
circulate through the pump to provide motor leads.
If the pump is located at the lowest point
in the piping system, the dirt and sediment adequate cooling and lubrication of the Fig. 8
in the system may collect inside the pump, pump's bearings and seals.
causing premature wear to the shaft seal. 2.4 Electrical Hookup
2.3.3 Proper Orientation Turn the incoming POWER OFF and make
VersaFlo TP pumps can be mounted either the proper electrical connections according
vertically or horizontally, and all positions to the diagram on the motor and the latest
in between. However, the motor shaft edition of the National Electrical Code.
must never fall below the horizontal plane.
Do not start the pump even to check
the direction of rotation until it has Single phase motors - touching the leads
been filled with water. The pump may be of the ohmmeter to the two outgoing "hot"
seriously damaged if it is run dry. motor leads (either a single motor lead or
combination of leads joined together) will
3. Starting the Pump the First Time measure the main winding's resistance.
3.1 Prime the Pump Three phase motors - touching the leads
of the ohmmeter to any two hot leads will
3.1.1. In Closed/Open System Where Water measure that winding's resistance. Repeat
Recommended
Source is Above the Pump for all three possible lead combinations (L1
and L2, L2 and L3, L1 and L3).
X
1. Close the pump isolation valves and
open the air vent screw. 5.1.3.2 Evaluation
DO NOT mount motor 2. Gradually open the suction isolation If all ohm values are normal, the motor
with shaft below windings are neither shorted nor open.
horizontal plane valve until a steady stream of airless
water runs out the air vent hole.
6 11
4.1.8 Service Conditions 3. Tighten the air vent screw and When viewed from the motor end, the
completely open the isolation valves. pump should rotate counter-clockwise.
Ambient Grease f. To reverse the direction of rotation,
Severity of Temperature Atmospheric Interval Approved 3.1.2 In Open Systems
TURN OFF the power supply and
Service (maximum) Contamination (hrs.) Types of Grease 1. The suction pipe and pump must be complete the following which applies.
filled and vented of air before starting
Standard 104F (40C) Clean, little corrosion 5500 Shell Dolium R the pump. On three-phase motors, interchange
any two power leads at the load
Severe 122F (50C) Moderate dirt, corrosion 2750 Chevron SR#2 2. Close the discharge side isolation valve side of the starter. On single-phase
Extreme >122F (50C) Severe dirt, abrasive 550 Or compatible and open the air vent screw and suction motors, refer to the connection
valve. diagram on the motor nameplate.
or class H ins. dust, corrosion equivalent grease
3. Fill the suction line through the plugged Change the wiring as required.
tee or capped pipe (if one is installed). If g. TURN ON the power and again check for
not possible, remove one of the gauge proper motor rotation.
If the pump fails to operate or there Evaluation tapping plugs in the pump flanges and
is a loss of performance, refer to the pour water into the hole using a funnel 3.3 Starting and Adjusting
When the motor is under load, the voltage
Troubleshooting section on pages 11 or hose with an adapter.
should be within 10% of the nameplate a. Make sure that:
through 14.
voltage. Larger voltage variation may Fig. 3 The pump has been primed.
4.1.9 Rapid Cycling cause winding damage and indicate a poor
electrical supply. The pump should not be The rotation is counter-clockwise
Pump cycling should be monitored to
operated until these variations have been when viewed from the motor end.
make sure the pump is not starting more
corrected.
than 20 times per hour. If it is, premature The piping connections are tight and
motor failure is quite likely, due to the If the voltage constantly remains high or Air adequately supported.
increased heat build-up in the motor. Make low, the motor should be changed to the venting
screw b. Open the suction line valve completely
any adjustments to controls ne-cessary to correct supply voltage.
(if one is installed).
reduce the frequency of stops and starts.
Fig. 6
c. Close the isolation valve in the discharge
4.1.10 Freeze Protection pipe. It should be opened gradually
Gauge
If the pump is installed in an area where Tapping after the pump is turned on. Opening
freezing could occur, the pump and plugs (2) the valve too fast may result in water
system should be drained during freezing hammer in the discharge pipe.
temperatures to avoid damage. d. Start the pump.
To drain the pump, close both isolation e. Gradually open the isolation valve in the
valves and loosen the suction and dis- discharge piping as explained in step c.
charge flanges. Allow water to flow out of Open the valve completely.
the pump before reconnecting the pump
to the flanges. Do not tighten the flanges f. Check the voltage and amperage at
completely until the pump is ready to be the motor and record them. Adjust the
used again. motor overloads if required.
All air in the pump and suction line must g. If pressure gauges have been installed,
5. Troubleshooting be purged before starting the pump. check and record the values as the pump
5.1 Preliminary Checks 3.2 Check the Direction of Rotation operates.
5.1.2 Current Measurement h. Check all controls for proper operation.
5.1.1 Supply Voltage a. Switch the POWER OFF.
5.1.2.1 How to Measure If the pump is controlled by a pressure
5.1.1.1 How to Measure b. Check to make sure the pump has been switch, check and adjust the cut-in and
Use an ammeter, (set on the proper scale) filled and vented. cut-out pressures. If low-water level
Use a volt meter, (set to the proper scale) to measure the current on each power lead controls are used, be sure the low-level
measure the voltage at the pump terminal c. Remove the coupling guard and rotate
at the terminal box or starter. the pump shaft to be certain it turns switch is properly adjusted so the pump
box or starter. cannot run if the pump breaks suction.
Current should be measured when the freely. Replace the coupling guard.
On single-phase units, measure between pump is oper-ating at constant discharge d. Verify that the
power leads L1 and L2 (or L1 and N for 115 pressure. electrical connections
4. Maintenance
volt units). On three-phase units, measure R CLOCK
TE
between: 5.1.2.2 Evaluation are in accordance with 4.1 Servicing the Pump Head
W
COU
the wiring diagram on
ISE
Power leads L1 and L2 If the amp draw exceeds the listed the motor. 4.1.1 Step 1: Remove the Pump Head
service factor amps (SFA) or if the current
Power leads L2 and L3 e. Switch the power 1. Turn OFF the power to the motor.
imbalance is greater than 5% between
Power leads L3 and L1 each leg on three-phase units, check the on and observe the 2. Close any isolation valves on either
following: direction of rotation. side of the pump.
10 7
Fig. 4 5. Clean the recess of the pump housing/ pump housing, do not attempt to rotate flowing through the pump. The motors will
Terminal motor stool lubricate o-ring with soapy the pump head, since doing so may require periodic lubrication as noted in the
Box water if necessary. damage the O-ring. following paragraphs.
6. Fit the pump head in the pump housing 3. Make sure the pump head assembly is
Pump
4.1.5 Motor Lubrication
Powerhead
Motor with the terminal box in the required properly seated on the pump housing.
Stool
position, be careful to align impeller DO NOT force the two together. Electric motors are prelubricated at the
Head
with neck ring. factory and do not require additional
Hex
4. Tighten two of the hex bolts opposite lubrication at start-up. Motors without
Screws 7. Replace the motor stool bolts and each other until the pump head is external grease fittings have sealed
tighten to the following specifications. secure to the pump housing. bearings that cannot be relubricated.
O-Ring
M8. . . . . . . . . . . . . . . . . . . . 18.4 ft lbs 5. Check to make sure the motor shaft Motors with grease fittings should only be
turns freely. lubricated with approved types of grease.
Impeller M10 . . . . . . . . . . . . . . . . . . . 34.7 ft lbs
Stainless Steel 6. Insert and tighten the rest of the hex Do not over grease the bearings. Over
Seal Ring 8. Check the shaft for free rotation and greasing will cause increased bearing heat
(inside) bolts evenly to secure the pump head
replace the coupling guards. and can result in bearing/motor failure.
assembly.
Do not mix petroleum grease and silicon
Pump 9. The pump is now completely assembled. Hex Bolt Torque grease in motor bearings.
Housing
13 mm . . . . . . . . . . . . . . . 19 ft lbs Bearing Grease will lose its lubricating
Fig. 5 ability over time, not suddenly. The
3. Disconnect the electrical leads and 17 mm. . . . . . . . . . . . . . . . 35 ft lbs
lubricating ability of the grease (over time)
conduit from the terminal box. 4.1.3 Motor Replacement depends primarily on the type of grease,
4. Loosen and remove the hex bolts the size of the bearings, the speed at which
If the motor is damaged due to bearing
connecting the pump head assembly to the bearings operate and the severity of
failure, or electrical failure, the following
the pump housing. Note the position the operating conditions.
instructions detail how to remove the
of the motor terminal box relative motor for replacement. It must be Good results can be obtained if the
to the pump housing. emphasized that motors used on VersaFlo following recommendations are used in
5. Remove the pump head assembly TP pumps are specifically selected to our your maintenance program.
from the pump housing. rigid specifications.
4.1.6 Lubrication Schedule
6. Clean the machined surfaces in the Replacement motors must be of the same
NEMA frame size, should be equipped with For motor frame sizes smaller than 210TC,
pump housing. add 0.3 oz. (8.4g) or 0.6 in.3 (2 tsp.) at the
the same or better bearings and have the
7. Inspect the pump housing and stainless same service factor. Failure to follow these intervals listed above.
steel ring for any damage. Check to be recommendations may result in premature 4.1.7 Periodic Safety Checks
sure the seal ring is mounted securely in motor failure.
the pump housing. At regular intervals depending on the
4.1.3.1 Disassembly conditions and time of operation, the
8. Repair or replace parts as needed. following checks should be made:
1. Remove the coupling guard screens.
4.1.1.1 Assembly 1. Pump meets required performance and
2. Using the proper metric allen wrench,
With the motor/motor stool assembly loosen the four cap screws in the is operating smoothly and quietly.
upside down as shown (fig. 5) coupling, fully remove coupling halves. 2. There are no leaks, particularly at the
1. Carefully pass the shaft with the 3. With the correct size wrench, loosen and shaft seal.
rotating shaft seal and impeller through remove the four bolts which hold the 3. The motor is not overheating.
the shaft hole in the motor stool (the motor to the discharge section of the
seal rings must not be exposed to blows pump end. 4. Remove and clean all strainers or filters
or knocks). in the system.
4. Lift the motor straight up until the shaft
2. Fit the shaft pin in the shaft pin hole. is free from the coupling. 5. Verify the tripping of the motor
overload protection.
3. Fit the coupling halves and the coupling 4.1.4 Pump Lubrication
allen bolts loosely to the pump and 6. Check the operation of all controls.
motor shafts so that the gaps on both Grundfos VersaFlo TP in-line centrifugal Check unit control cycling twice and
sides of the coupling halves are even. pumps installed in accordance with adjust if necessary.
4.1.2 Step 2: Re-Install the Pump Head
these instructions and sized for correct
4. Insert a screwdriver above the coupling, 7. If the pump is not operated for
1. Lubricate the O-ring with soapy water. performance will operate efficiently and
push the pump shaft towards the motor unusually long periods, the unit should
provide years of service.
as far as possible. The pump and motor 2. With the motor terminal box in the be maintained in accordance with these
shaft should touch each other. Tighten desired position, carefully place the The pumps are lubricated by the fluid they instructions. In addition, if the pump
coupling allen bolts to the following pump head assembly into the pump pump, and do not require any additional is not drained, the pump shaft should be
specifications: housing. Be careful not to damage the lubrication. However, this also means the manually rotated or run for short
impeller or mating seal ring. Once the pump should never be operated for any periods of time at monthly intervals.
M6 . . . . . . . . . . . . . . . . . 9.6 ft lbs pump head O-ring is engaged with the prolonged periods of time without fluid
M8. . . . . . . . . . . . . . . . .22.6 ft lbs
8 9